Method for manufacturing and golf club head

ABSTRACT

A method for forming a golf club head comprises placing an uncured composite material between a core and a mold that comprises a first piece and a second piece. The second piece is moved towards the first piece such that the uncured composite material is compressed between the core and at least a portion of the mold. The uncured composite material is heated. A first portion of the golf club head is removed from the mold. A second portion of the golf club head is provided. The first portion is attached to the second portion. In certain arrangements, the second portion is formed from a metallic material.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to an improved method for producinga golf club head, and more particularly to an improved method ofproducing a club head made of a carbon fiber composite.

[0003] 2. Description of the Related Art

[0004] A wood-type golf club typically includes a hollow shaft with aclub head attached to the lower end of the shaft. The club headtypically includes a load-bearing outer shell with an integral orattached strike plate. The strike plate defines a substantially planarfront surface or strike face for striking a golf ball.

[0005] A recent trend in the industry is to make the club head out ofstrong, yet lightweight material, such as, for example, titanium, atitanium alloy or a carbon fiber composite. Of these materials, carbonfiber composites are particularly interesting to golf club designersbecause it has a density that is roughly one third of the density oftitanium but is almost as strong as titanium. Accordingly, carbon fibercomposites are particularly suitable for very large club heads (i.e.,club heads that define an internal volume greater than 400 centimeterscubed).

[0006] Despite their low density and strength, club heads that are madeentirely of carbon fiber composites are generally not popular. This isdue, in part, to the relatively high stiffness that is typical of carbonfiber composites. Such stiffness usually is undesirable especially inthe strike plate. Moreover, carbon fiber composites are not particularlydurable. Thus, composite club heads have a tendency to wear out in theareas that are subjected large amounts of wear and friction (e.g., thesole of the club head).

[0007] To overcome some of these problems, it has been suggested thatthe club head be made from a combination of titanium or alloy and carbonfiber composites. Specifically, it has been suggested that a club headcan be formed from an outer shell made of a carbon fiber composite,which is attached to a strike plate made of a titanium or a titaniumalloy. However, existing methods for manufacturing such a club have notbeen satisfactory. For example, one golf club manufacturer attempted toco-cure a metal strike plate with a composite outer shell. Morespecifically, a metal strike plate was placed in a mold along with aninflatable bladder that was surrounded by a uncured composite material.To cure the composite, the bladder was inflated to press the uncuredmaterial against the mold and the strike plate. However, fitting thestrike face into mold and removing the bladder from the cured club headwas difficult and time consuming.

SUMMARY OF THE INVENTION

[0008] An aspect of the present invention is an improved method forproducing a club head comprising of a metal strike plate and a compositeshell. A further aspect of the present invention is the realization thatsuch a club can be produced by attaching the metal strike plate to thecomposite shell after the composite shell is formed. However, for themetal strike plate to be successfully attached to the strike plate thecomposite shell must be produced in a manner that ensures tighttolerances and smooth surfaces on both the inside surfaces and outsidesurfaces of the shell.

[0009] Accordingly, one aspect of the invention is a method for forminga golf club head. The method comprises placing an uncured compositematerial between a core and a mold that comprises a first piece and asecond piece. The second piece is moved towards the first piece suchthat the uncured composite material is compressed between the core andat least a portion of the mold. The uncured composite material isheated. A first portion of the golf club head is removed from the mold.A second portion of the golf club head is provided. The first portion isattached to the second portion.

[0010] Another aspect of the invention is a method for forming a golfclub head. The method comprises placing an uncured composite materialbetween a core and a mold that comprises a first piece and a secondpiece. The second piece is moved towards the first piece such that theuncured composite material is compressed between the core and at least aportion of the mold. The uncured composite material is heated. A firstmating section is formed on the first portion. A first portion of thegolf club head is removed from the mold. A second portion of the golfclub head is provided. The first portion is attached to the secondportion.

[0011] Yet another aspect of the invention is a golf club headcomprising a shell made of a composite material that is attached to astrike plate that is formed of a metallic material. material. The shellincludes a first mating section and the strike plate including a secondmating section configured to mate with the first mating section.

[0012] Still yet another aspect of the present invention is a golf clubhead comprising a shell made of a composite material that is attached toa strike/sole plate combination. The strike/sole plate combinationincludes strike plate and sole plate, which are integrally formed andmade of a metallic material. The shell includes a first mating sectionand the strike/sole plate combination includes a second mating sectionconfigured to mate with the first mating section.

[0013] For purposes of summarizing the invention and the advantagesachieved over the prior art, certain objects and advantages of theinvention have been described herein above. Of course, it is to beunderstood that not necessarily all such objects or advantages may beachieved in accordance with any particular embodiment of the invention.Thus, for example, those skilled in the art will recognize that theinvention may be embodied or carried out in a manner that achieves oroptimizes one advantage or group of advantages as taught herein withoutnecessarily achieving other objects or advantages as may be taught orsuggested herein.

[0014] All of these embodiments are intended to be within the scope ofthe invention herein disclosed. These and other embodiments of thepresent invention will become readily apparent to those skilled in theart from the following detailed description of the preferred embodimentshaving reference to the attached figures, the invention not beinglimited to any particular preferred embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] These and other features of the invention will now be describedwith reference to the drawings of a preferred embodiment, which areintended to illustrate and not to limit the invention, and in which:

[0016]FIG. 1 is a front perspective view of a golf club head havingcertain features and advantages according to the present invention;

[0017]FIG. 2 is a rear perspective of the golf club head of FIG. 1;

[0018]FIG. 3A is a cross-sectional view of the golf club head of FIG. 1;

[0019]FIG. 3B is an enlarged cross-sectional view of the area with thecircle labeled 3B of FIG. 3A;

[0020]FIG. 3C is a cross-sectional view of a modified arrangement of agolf club head;

[0021]FIG. 4 is a side perspective view of a strike/sole platecombination and outer shell of the club head of FIG. 1;

[0022]FIG. 5 is a top view of the strike/sole plate combination of FIG.4;

[0023]FIG. 6 is a cross-sectional view of a mold according to a methodin the prior art;

[0024]FIG. 7 is cross-sectional view of a mold according to anothermethod in the prior art;

[0025]FIG. 8 is a perspective view of a mold for a golf club head havingcertain features and advantages according to the present invention;

[0026]FIG. 9A is a front view of a core of the mold of FIG. 8;

[0027]FIG. 9B is a right side view of the core;

[0028]FIG. 9C is a left side view of the core;

[0029]FIG. 9D is a top view of the core;

[0030]FIG. 9E is a bottom view of the core;

[0031]FIG. 10 is a cross-sectional view of the mold of FIG. 8;

[0032]FIG. 11A is a top view of a first mold piece of the mold of FIG.8;

[0033]FIG. 11B is a front view of the first mold piece;

[0034]FIG. 12A is front view of a second mold piece of the mold of FIG.8; and

[0035]FIG. 12B is a bottom view of the second mold piece.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0036] FIGS. 1-5 illustrated a club head 10 having certain features andadvantages according to the present invention. With initial reference toFIG. 1, the club head 10 comprises a strike plate 12. The strike plate12 defines a substantially planar front surface or strike face 14 forimpacting a golf ball. A hosel 16 extends upward from the strike plate12. The hosel 16 is configured to be coupled to a golf club shaft (notshown) in a well known manner. The strike plate 12 is preferably made ofa strong, yet lightweight metal, such as, for example, titanium or atitanium alloy.

[0037] The club head 10 also comprises an outer shell 20 that ispreferably made of a strong yet lightweight composite material, such as,for example, a carbon fiber reinforced epoxy or carbon fiber reinforcedpolymer. As best seen in FIG. 3A, the outer shell 20 includes an innersurface 21, which defines an interior volume 22 of the club head 10, andan outer surface 23. The club head 10 also includes a toe region 24 anda heel region 26, as is well known. The bottom of the club head 10 isdelimited in part by a sole 28 and the top of the club head is delimitedby a crown 30.

[0038] With particular reference to FIGS. 2 and 4, the illustrated clubhead 10 also comprises a sole plate 32, which extends along the centerof the sole 28 from the strike plate 12 to the rear of the club head 10.As best seen in FIG. 4, in the illustrated arrangement, the sole plate32 is formed integrally with the strike plate 12. That is, the soleplate 32 and the strike plate 12 form a single strike/sole platecombination 34. The outer shell 20 preferably is attached to thissole/strike plate combination 34, as will be described in more detailbelow. The sole plate 32 protects the 28 sole of the club head 10 fromfriction and wear during a golf swing. Accordingly, the sole plate 32preferably is made of a material that is more durable than the shell 20,such as, for example, a metal. More preferably, the sole plate 32 ismade of the same strong, yet lightweight metal as the strike plate 12.It should be appreciated, however, that several features and advantagesof the present invention can be achieved in an arrangement wherein thestrike plate 12 and the sole plate 32 are not integrally formed (i.e.,the strike plate 12 and the sole plate 32 are separate pieces).Moreover, in some arrangements of the present invention, the club head10 can be formed without the sole plate 32. In other arrangements, theclub head 10 can be formed without the strike plate 12. However, theillustrated arrangement is preferred because the mechanical propertiesof metal are particularly suited for the strike plate 12 and the soleplate 32. As mentioned above, the strike plate 12 and the sole plate 32are preferably made of a strong, yet light weight metal, such as, forexample, titanium. In such an arrangement, the strike plate 12 and/orthe sole plate 32 can be formed by casting, forging, rolling or acombination of casting, forging and/or rolling.

[0039]FIG. 3C illustrates another arrangement of the club head 10. Inthis arrangement, the club head 10 includes an inner shell 35 that ispreferably integrally formed with the strike/sole plate combination 34.In this arrangement, the inner shell 35 defines the inner surface 21 ofthe club head 35. The inner shell 35 is preferably made of the samestrong, yet lightweight metal as the strike/sole plate combination. Theouter surface 23 of the club head 10 is defined by the outer shell 20,which surrounds the inner shell 35 and is preferably made of a strongyet lightweight composite material, such as, for example, a carbon fiberreinforced epoxy or carbon fiber reinforced polymer.

[0040] As mentioned above, the outer shell 20 preferably is attached tothe strike/sole plate combination 34. To improve the strength of theconnection between the outer shell 20 and the strike/sole platecombination 34, the outer shell 20 and the strike/sole plate combination34 preferably include an interlocking joint 36, which is best seen inFIGS. 3A and 3B. In the illustrated embodiment, the joint 36 comprisesmating sections 38 a, 38 b formed on the outer shell 20 and thestrike/sole plate combination 34 respectively. Each mating section 38 a,38 b preferably includes an abutment surface 39 a, 39 b that istransverse to the outer surface 23. More preferably, the abutmentsurface 39 a, 39 b, lies substantially normal to the outer surface 23.The abutment 39 a, 39 b surfaces help to align the shell 20 with thestrike/sole plate combination 34 and to prevent lateral movement ofthese two components 20, 24 with respect to each other. Each matingsection 38 a, 38 b, preferably also includes an attachment surface 41 a,41 b. The attachment surfaces 41 a, 41 b are at least two (2) times, andpreferably, four (4) times as wide as the thickness t of the outer shell20. The attachment surfaces 41 a, 41 b preferably provide a surface foran adhesive as will be explained in more detail below. The attachmentsurfaces 41 a, 41 b preferably are generally parallel to the outersurface 23 of the shell 20 and midway between the inner surface 21 andouter surface 23 of the outer shell 20. This arrangement is preferredbecause it permits a longer attachment surface and thicker matingsections 38 a, 38 b, which increases the strength of the joint 36 andthe bond between the shell 20 and the strike/sole plate combination 34respectively. In the arrangement illustrated in FIG. 3C, the attachmentsurfaces 41 a, 41 b can extend along the entire length of the outershell 20.

[0041] As best seen in FIG. 4, the mating sections 38 a, 38 b,preferably extend completely along the interface between the outer shell20 and the strike/sole plate 34 combination. However, it should beappreciated that, in a modified arrangement, the mating sections 38 a,38 b could extend only partially along the interface between the outershell 20 and the strike/sole plate combination 34. In the illustratedarrangement, each piece 38 a, 38 b includes two abutment surfaces 39 a,39 b, which are separated by the attachment surfaces 41 a, 41 b. Thatis, the abutment surfaces 39 a, 39 b, and the attachment surfaces 41 a,41 b, form an interlocking steps. However, it should be appreciated thatthe mating sections 38 a, 38 b can be formed into a variety of othershapes giving due consideration to the preference of providing a secureconnection between the outer shell 20 and the strike/sole platecombination 34. For example, the mating sections 38 a, 38 b can comprisean interlocking tongue and groove arrangement or a matching inclinedsurface arrangement, each of which includes abutment surfaces 39 a, 39 band attachment surfaces 41 a, 41 b.

[0042] To permanently secure the outer shell 20 to the strike/sole platecombination 34, an adhesive, such as, for example, an epoxy is appliedto one or both of the mating sections 38 a, 38 b, preferably, along theattachment surfaces 41 a, 41 b. In a modified arrangement, the outershell 20 can be secured to the strike/sole plate combination 34 byfasteners that can extend through the joint 36. As best seen in FIG. 3Aand 5, the sole plate 32 preferably includes an annular rib 40, whichextends from the periphery of the sole plate 32 and into the cavity 22of the club head 10. The annular rib 40 advantageously increases therigidity of the sole plate 32. Of course, those of skill in the art willrecognize that the sole plate 32 can be formed without the annular rib40.

[0043] To ensure a secure bond between the outer shell 20 and thestrike/sole plate combination 34, the joint 36 (i.e., the interlockingstep surfaces 38 a, 38 b ) preferably are made with tight tolerances andsmooth surfaces. More preferably, these components are made with atolerance that is less than approximately ±0.15 millimeters . Withrespect to the interlocking step surface 38 a of the outer shell 20,prior methods for producing carbon fiber club heads are not adequate forcreating the desired tight tolerances and smooth surfaces. This isespecially true with respect to the inner surface 21 of the outer shell20 and the portion of which forms the interlocking step surface 38 a ofthe outer shell 20 (see FIG. 3B).

[0044] For example, FIG. 6 shows a cross-section of a carbon fiber clubhead being produced according to the methods of the prior art. Accordingto this technique, an uncured composite material 50 is wrapped around aninflatable bladder 52. The bladder 52 and the composite material 50 areplaced within a mold 54 and heated to a specified temperature to softenthe uncured composite. The bladder 52 then is inflated with pressurizedair, steam or oil through one or more openings 56. As the bladder 52expands, the composite material 50 is pressed against the inner surfaces55 of the mold 54. After the composite material 50 cures, the golf clubhead is removed from the mold 54 and the bladder 52 is deflated andremoved from the golf club through the one or more openings 56.

[0045] One problem with the above-described method is that it isdifficult to obtain tight tolerances and smooth surfaces on the interiorsurfaces 58 of the club head. This difficulty is due primarily to thenature of the inflatable bladder 52. As the bladder 52 expands, thecomposite material 50 is pressed against the hard smooth inner surface55 of the mold 54. This tends to produce a smooth surface on the outersurfaces 60 of the composite material. In contrast, the relativelyflexible surface of the inflatable bladder 52 presses against theinterior surfaces 58 of the composite material. This tends to produce anuneven surface, which makes it difficult to obtain the tight tolerancesand smooth surfaces.

[0046] A technique that is likely to be more successful in obtainingtight tolerance on the interior surfaces of the club head is shown inFIG. 7. This method uses, sheets 60 of fibrous material that are wrappedaround a core 62 made of a low melting point alloy. The core 62 and thefibrous material 60 are placed within a cavity of a splittable mold 64made of a pair of mold halves 66, 68. The fibrous material 60 lieswithin a peripheral gap is formed between the core 62 and the mold 68.Once the core 62 and fibrous material 60 are in place, resin is injectedinto the peripheral gap through an opening 70. The resin flows throughthe fibrous material and hardens to form the golf club head. The mold 68is heated to melt the core 62, which can be removed from a hole 72formed in the club head.

[0047] This method, however, has a number of significant drawbacks. Forexample, because the resin must flow through the fibrous material, thefiber loading of the fibrous material must be kept to a relatively smallamount. This reduces the strength of the final composite material. Themethod also requires the two halves 66, 68 of the mold 64 to be sealedso as to prevent the resin from leaking out of the mold 64. Thisincreases the cost of manufacturing.

[0048] To address the above-noted problems, Applicant has invented amethod for manufacturing a golf club having certain features andadvantages. The method utilizes a mold 98, which is shown in FIG. 8. Themold includes a core or mandrel 100, which is shown in detail in FIG.9A-E. The core preferably is made of a hard material, such as, forexample, aluminum or steel. Preferably, the core 100 comprises a firstpiece 102 a and a second piece 102 b. However, it should be appreciatedthat the core 100 can comprise a single piece or more than two pieces.The two piece construction is preferred for reasons that will be setforth below. The core 100 defines an exterior surface 104, whichcorresponds generally to the desired shape of the interior surface 21 ofthe outer shell 20. In particular, the exterior surface 104 includes aridge 106 that forms an analog to the interlocking step surface 38 a ofthe club head 10 (see FIG. 4). Of course, if the joint 36 has adifferent configuration the exterior surface 104 can be modifiedaccordingly.

[0049] The mold 98 also comprises a first mold piece 112, which is shownin FIGS. 8 and 10-11B. The first mold piece 112 includes an innersurface 114, which generally corresponds to the desired shape of aportion of the outer shell's 20 exterior surface 23. More specifically,in the illustrated arrangement, the inner surface 114 of the moldcorresponds to a lower portion (i.e., the portion of outer shell 20 thatlies generally below the crown 30) of shell's 20 exterior surface 23.The illustrated first mold piece 112 also includes a spacing groove 116.The groove 116 is configured to receive a tongue piece 118 that isformed on the core 100 (see FIGS. 9A, 9B, and 10). The tongue 118 andgroove 116 cooperate to properly align the core 100 within the cavity110. While the tongue 118 and groove 116 are preferred for thesimplicity and reliability, those skilled in the art will recognize thatthere are other ways to ensure the proper alignment of the core 100within the cavity 110.

[0050] The mold 98 further includes a second mold piece 120, which isshown in FIGS. 8, 10, 13 and 14. The second mold piece 120 has a secondinner surface 122, which preferably is configured to generallycorrespond to the desired shape of the crown 30. The top portion 120 isfurther configured such that it can be moved towards or away from thefirst mold piece 112. Accordingly, as shown in FIG. 8, the top portion112 is connected to the bottom portion 110 by a plurality of shafts 124,which are threaded. The shafts 124 preferably extend through threadedholes formed in the second mold piece 122 and threaded holes formed inthe first mold piece 112. Thus, the second mold piece 120 can be movedtowards the first mold piece 112 by rotating the shafts 120. Of course,those skilled in the art will recognize that there are other ways formoving the first and second mold pieces 112, 122 towards each other.

[0051] As shown in FIG. 8 and 10, the mold 98 preferably also includes athird mold piece 130. The third mold piece 130 includes a third innersurface 132, which is configured to contact a portion 134 of theexterior surface 104 of the core 100.

[0052] To form the outer shell 20 of the club head 10, an uncuredcomposite material 150 is placed (i.e., laying up) around the core 100(see FIG. 10). The uncured composite material 150 preferably is a carbonfiber reinforced thermoset resin or a carbon fiber reinforced plasticresin. The composite material 150 and the core 100 preferably are thenplaced within the first mold piece 112. Once the core 100 is in place,the third mold piece 130 is attached, preferably with bolts (not shown),to the first mold piece 112. In this position, the third mold piece 130securely holds the core 100 and composite material 150 within the firstmold piece 112.

[0053] The second mold piece 130 then is moved towards the first moldpiece 112. Accordingly, the uncured composite material 150 is compressedbetween the first, second mold pieces 112, 120 and the core 100. As thesecond mold piece 120 is moved towards the first mold piece 112, thelower surface 152 (see FIG. 10) of the second mold piece 120 eventuallycontacts the upper surface 154 of the first mold piece 112, resulting ina positive stop. Preferably, the first and second mold pieces 112, 120are configured such that when the lower and uppers surfaces 152, 154contact a uniform gap exists between the second piece 120 and the core100. In this manner, the composite material 150 is uniformly compressedbetween the first and second mold pieces 112, 120 and the core 100.

[0054] Preferably, while the composite material 150 is being compressed,the mold 98 is being heated in an oven to a temperature between 200-500degrees Fahrenheit. More preferably, the mold 98 is heated to atemperature of approximately 350 degree Fahrenheit for approximately 10minutes. The compressing and heating cures the composite material 150into the desired shape, which is determined by the shape of the core 100and the inner surfaces 114, 122 of the first and second mold pieces 112,120.

[0055] After the composite material 150 is cured, the second and thirdmold pieces are removed. The core 100 can then be removed form the curedshell 20. The illustrated two piece construction of the core 100 aidesthe removal of the core 100. The finished shell 200 is removed from themold 98 and attached to a corresponding strike/sole plate 34 combinationwith epoxy as described above.

[0056] In the illustrated arrangement, the strike/sole plate combination34 is made of titanium or a titanium alloy. This arrangement ispreferred because the material properties of titanium are particularlysuited for the strike plate 12 and the sole plate 32. However, it shouldbe appreciated that, in a modified arrangement, the above-describedmethod can also be utilized for a club head wherein the strike plate 12and/or the sole plate 32 are made of a composite material. In such anarrangement, a second mold (not shown) can be formed utilizing theprinciples described above. The second mold can be used to create astrike plate, a sole plate, or a strike/sole plate combination made of acomposite material.

[0057] In another modified arrangement, the core 100 is attached to orintegrally formed with the first mold piece 112. In such an arrangement,the uncured composite material 150 is placed over the core 100. Thesecond mold piece 130 then is moved towards the first mold piece 112.After the composite material cures, the composite material 150 can beremoved from the first mold piece 112.

[0058] Although this invention has been disclosed in the context ofcertain preferred embodiments and examples, it will be understood bythose skilled in the art that the present invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the invention and obvious modifications and equivalentsthereof. In addition, while a number of variations of the invention havebeen shown and described in detail, other modifications, which arewithin the scope of this invention, will be readily apparent to those ofskill in the art based upon this disclosure. It is also contemplatedthat various combination or subcombinations of the specific features andaspects of the embodiments may be made and still fall within the scopeof the invention. Accordingly, it should be understood that variousfeatures and aspects of the disclosed embodiments can be combine with orsubstituted for one another in order to form varying modes of thedisclosed invention. Thus, it is intended that the scope of the presentinvention herein disclosed should not be limited by the particulardisclosed embodiments described above, but should be determined only bya fair reading of the claims that follow.

What is claimed is:
 1. A method for forming a golf club head comprising:placing an uncured composite material between a core and a mold thatcomprises a first piece and a second piece; moving the second piecetowards the first piece such that the uncured composite material iscompressed between the core and at least a portion of the mold; heatingthe uncured composite material; removing a first portion of the golfclub head from the mold; providing a second portion of the golf clubhead; and attaching the first portion to the second portion.
 2. Themethod of claim 1, wherein providing the second portion comprisesforming the second portion out of a metallic material.
 3. The method ofclaim 2, wherein forming the second portion further includes casting thesecond portion out of the metallic material.
 4. The method of claim 2,wherein forming the second portion further includes forging the secondportion out of the metallic material.
 5. The method of claim 2, whereinforming the second portion further includes a combination of casting andforging the second portion out of the metallic material.
 6. The methodof claim 1, wherein providing the second portion comprises placing asecond uncured composite material between a second core and a secondmold that comprises a third piece and a fourth piece, moving the fourthpiece towards the third piece such that the second uncured compositematerial is compressed between the second core and at least a portion ofthe second mold; and heating the second uncured composite material. 7.The method of claim 1, wherein the first portion comprises a shell ofthe club head and the second portion comprises a strike/sole platecombination.
 8. The method of claim 1, wherein the first portioncomprises a shell of the club head and the second portion comprises astrike plate.
 9. The method of claim 1, wherein the first portioncomprises a shell of the club head and the second portion comprises asole plate.
 10. The method of claim 1, wherein the uncured compositematerial is a carbon reinforced thermoset resin.
 11. The method of claim1, wherein the uncured composite material is a carbon reinforced plasticresin.
 12. The method of claim 1, wherein placing the uncured compositematerial between the core and the mold includes laying up the uncuredcomposite material around the core and placing the core and uncuredcomposite material in the mold.
 13. The method of claim 1, wherein saidouter mold further comprises a third piece and the method furthercomprises attaching the third piece to the first piece.
 14. A method forforming a golf club head comprising: placing an uncured compositematerial between a core and a mold that comprises a first piece and asecond piece; moving the second piece towards the first piece such thatthe uncured composite material is compressed between the core and atleast a portion of the mold; heating the uncured composite material;forming a first mating section on the first portion; removing a firstportion of the golf club head from the mold; providing a second portionof the golf club head; and attaching the first portion to the secondportion.
 15. The method of claim 14, further comprising forming secondmating section on the second portion, the second mating sectionconfigured to mate with the first mating section.
 16. The method ofclaim 15, wherein attaching the first portion to the second portionfurther includes applying an adhesive between the first mating sectionand the second mating section and fitting together the first matingsection and the second mating section.
 17. The method of claim 14,wherein forming the first mating section includes forming an abutmentsurface, which is transverse to an outer surface of the first portion ofthe club head.
 18. The method of claim 14, wherein forming the firstmating section includes forming an attachment surface, which isgenerally parallel to an outer surface of the first portion.
 19. Themethod of claim 14, wherein forming the first mating section includesforming a first abutment surface, which is transverse to an outersurface of the first portion of the club head and a first attachmentsurface, which is generally parallel to an outer surface of the firstportion.
 20. The method of claim 19, wherein providing the secondportion includes forming a second mating section configured to mate withthe first mating section, the second mating section including a secondabutment surface configured to mate with the first abutment surface anda second attachment surface configured to mate with the first abutmentsurface.
 21. The method of claim 20, wherein attaching the first portionto the second portion includes applying an adhesive between the firstattachment surface and the second attachment surface and fittingtogether the first mating section with the second mating section. 22.The method of claim 14, wherein the uncured composite material is acarbon reinforced thermoset resin.
 23. The method of claim 14, whereinthe uncured composite material is a carbon reinforced plastic resin. 24.The method of claim 14, wherein heating the uncured composite materialcomprises heating the uncured composite material to a temperaturebetween approximately 200-500 degrees Fahrenheit.
 25. The method ofclaim 14, wherein heating the uncured composite material comprisesheating the composite material to a temperature of approximately 350degrees Fahrenheit.
 26. The method of claim 14, wherein heating theuncured composite material comprises heating the composite material to atemperature of approximately 350 degrees Fahrenheit for approximately 10minutes.
 27. The method of claim 14, wherein placing the uncuredcomposite material between the core and the mold includes laying up theuncured composite material around the core and placing the core anduncured composite material in the mold.
 28. The method of claim 14,wherein said outer mold further comprises a third piece and the methodfurther comprises attaching the third piece to the first piece.
 29. Agolf club head comprising a shell made of a composite material that isattached to a strike plate that is formed of a metallic material, theshell including a first mating section and the strike plate including asecond mating section configured to mate with the first mating section.30. The golf club head of claim 29, wherein the first mating section andthe second mating section extend entirely along an interface between theshell and the strike plate.
 31. The golf club head of claim 29, whereinthe first mating section includes a first abutment surface, which istransverse to an outer surface of the shell and the second matingsection includes a second abutment surface, which is substantiallyparallel to the first abutment surface.
 32. The golf club head of claim29, wherein the first mating section includes a first attachmentsurface, which is generally parallel to an outer surface of the shelland the second mating section includes a second attachment surface,which is substantially parallel to the first attachment surface.
 33. Thegolf club head of claim 29, wherein the first mating section includesforming a first abutment surface, which is transverse to an outersurface of the shell and a first attachment surface, which is generallyparallel to an outer surface of the first portion and the second matingsection includes a second abutment surface that is substantiallyparallel to the first abutment surface and a second attachment surfacethat is substantially parallel to the first attachment surface.
 34. Thegolf club head of claim 29, wherein adhesive secures the first matingsection to the second mating section.
 35. A golf club head comprising ashell made of a composite material that is attached to a strike/soleplate combination that includes strike plate and sole plate which areintegrally formed and made of a metallic material, the shell including afirst mating section and the strike/sole plate combination including asecond mating section configured to mate with the first mating section.36. The golf club head of claim 35, wherein the first mating section andthe second mating section extend entirely along an interface between theshell and the strike/sole plate combination.
 37. The golf club head ofclaim 35, wherein the first mating section includes a first abutmentsurface, which is transverse to an outer surface of the shell and thesecond mating section includes a second abutment surface, which issubstantially parallel to the first abutment surface.
 38. The golf clubhead of claim 35, wherein the first mating section includes a firstattachment surface, which is generally parallel to an outer surface ofthe shell and the second mating section includes a second attachmentsurface, which is substantially parallel to the first attachmentsurface.
 39. The golf club head of claim 35, wherein the first matingsection includes forming a first abutment surface, which is transverseto an outer surface of the shell and a first attachment surface, whichis generally parallel to an outer surface of the first portion and thesecond mating section includes a second abutment surface that isgenerally parallel to the first abutment surface and a second attachmentsurface that is generally parallel to the first attachment surface. 40.The golf club head of claim 35, wherein adhesive secures the firstmating section to the second mating section.